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1983 KZ440 LTD starter removal 06 Jun 2022 14:25 #868374

  • PappaG
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New member here. My starter died and trying to figure out why the starter cover on the left site has a springy resistance while trying to remove it. Even if it is cocked at an angle it feels like a spring is holding it in. Pull on it and it just pulls itself back. Don’t want to damage anything. It doesn’t feel like a suction type pull back. Yes, the shifter and shifter cover were removed in case you were wondering.
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Last edit: by Street Fighter LTD.

1983 KZ440 LTD starter removal 06 Jun 2022 17:12 #868387

  • TexasKZ
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You are asking about the small, rectangular, chrome cover on top of the transmission, right? Remove the two screws, and it should pop off easily. Perhaps a previous owner put some sealer on it.

See page 74 for the procedure.
www.kzrider.com/modules/ServiceManuals/kz440.pdf
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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1983 KZ440 LTD starter removal 06 Jun 2022 17:49 #868389

  • Nebr_Rex
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There is a gasket under the cover that could be sticking.
The two bolts are all that is holding the cover in place.


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2002 ZRX1200R
81 GPz1100
79 KZ1000st daily ride
79 KZ1000mk2 prodject
78 KZ650sr
78 KZ650b
81 KZ750e
80 KZ750ltd
77 KZ400/440 cafe project
76 KZ400/440 Fuel Injected

www.dotheton.com/forum/index.php?topic=39120.0


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1983 KZ440 LTD starter removal 06 Jun 2022 18:07 #868390

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I am talking about the cover in my photo that has the Kawasaki emblem on it. After removing all the screws from the cover and pulling it off about an inch, something that feels like a spring is pulling it back. The gasket remained on the engine case so it’s not the gasket. It’s not like a suction pull like a shaft in a bore, Even if I cock it on an angle about 2 inches on one side it wats to pull itself in towards the engine case.

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1983 KZ440 LTD starter removal 06 Jun 2022 18:17 #868391

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The cover I am talking about is the one in my photo that has the Kawasaki emblem on it. After removing all the screws and I can pull it off about an inch and then the cover pulls itself back towards the engine case like a spring is pulling on it. It’s not like a suction pull like a tight fitting shaft in a bore. Even if I cock it about 2 inches on one side it just wants to pull itself back. Just to be clear, the chrome rectangular starter cover, the (2) starter bolts, the shifter lever and shifter lever cover have been all removed.

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Last edit: by PappaG.

1983 KZ440 LTD starter removal 06 Jun 2022 18:58 #868392

  • Nerdy
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That's your generator cover; there are magnets in there.



1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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1983 KZ440 LTD starter removal 06 Jun 2022 19:13 #868393

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Thanks, but I am talking about the left hand cover shown in my photo that has the starter gear and starter clutch behind it. The shifter lever and shifter lever cover have been removed, it’s just the adjoining cover I am referring to.

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1983 KZ440 LTD starter removal 06 Jun 2022 19:19 #868394

  • Mikaw
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You can lead a horse to water……..
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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1983 KZ440 LTD starter removal 06 Jun 2022 19:33 #868395

  • Nerdy
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Yes, I know. You said "The cover I am talking about is the one in my photo that has the Kawasaki emblem on it". That is the generator cover. There are also two wires running to the generator/alternator.

Go here and look at pages 71-72 in the manual: kzrider.com/modules/ServiceManuals/kz440.pdf

Observe that the end of the starter is also under that cover.
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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1983 KZ440 LTD starter removal 07 Jun 2022 09:01 #868415

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I have looked at that before and after looking at the exploded view drawing again I now figured that it is the alternator wire lead grommet causing the resistance (that springy feeling) as I had not removed the alternator wire grommet off of the housing. I know feel like an idiot. Thanks so much for your help!
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